No ifs, No T-butts…introducing the Composite Steam Boiler...

Boiler Operation Accreditation courses in Qatar

BG03 - Blowdown Systems

Guidance for Industrial Steam Boilers

Blowdown Systems, Guidance for Industrial Steam Boilers (Ref:BG03) is a guidance document intended to provide advice to designers, specifiers, manufacturers, installers and those responsible for the management and operation of steam plant as well as Competent Persons (CP). It is applicable to both new and existing installations of steam boilers and addresses the following issues:

The safe discharge of blowdown from boilers;

The safe use and operation of blowdown vessels;

The safe use and operation of blowdown pits;

Proper maintenance and inspection of blowdown vessels and pits including requirements for regular inspection by a Competent Person in accordance with the Written Sheme of Examination (WSE)

MCL Energy seal the deal with Akcros Chemicals

Akcros Chemicals is the leading chemical additive suppliers into the PVC and polymers industries and is expanding its range to cover a wider variety of additives in the coatings, rubber, silicones and sealants markets. Eccles represents the principle manufacturing and research site for their global operations.

The term contract comprises all routine maintenance and combustion support to maximise plant reliability and optimise cycle efficiencies to reduce gas consumption in the steam generation process. MCL Energy will monitor plant, back up for remote access, provide callout and service all the steam boiler plant and associated systems.

Ian Benbow, Site Engineering HSE Manager stated “We decided to award the term contract to MCL Energy based on MCL’s expertise in this specialist field, competitive cost base and capability to ensure our site receives reliable, economic steam supplies for our production process”

For more details on our industrial process portfolio and site energy services please contact Business Development on 01302 738000 or visit www.mclenergy.co.uk

MCL Energy 'linked' with New Energy Centre for World Class Adhesives Manufacturer

Established Technical Energy Services Provider MCL Energy Was Awarded A Prestigious Long Term Contract To Design, Build, Finance And Operate A New Energy Centre For Leading Structural Adhesives Manufacturer Huntsman Advanced Materials (UK) Ltd.

Huntsman Advanced Materials is a leading global supplier of structural adhesives for joining composite materials with a primary global manufacturing and distribution site based at Duxford.

Jason Perry, Sales Director said “We are looking forward to working together with Huntsman Advanced Materials and providing a first class Energy Centre. This long term solution enables Huntsman to move forward, assured that their new Energy Centre will provide efficient process steam for manufacturing.”

For more details on energy and technical service solutions please call Business Development on 01302 738000 or visit www.mclenergy.co.uk

Fulton's move to new Bristol-based facility

Fulton's move to new Bristol-based facility will see pressure vessel manufacturing return to the UK

Heat transfer specialist Fulton Limited is moving to a new 43,000 sq. ft. Bristol-basedheadquarters on Monday, 3 June 2013.

The Fulton name has been synonymous with steam since 1949 when the company introduced the vertical tubeless steam boiler in the USA. The UK company, which was founded in Bristol in 1966, is now established as a leading manufacturer of thermal heat transfer systems for applications such as water heating, steam sterilisation and processing.

Announcing the move, managing director Paul Richards says: “The move to the new facility, also in Bristol, will help us manage current demand, and plan for the future. The increased space will also allow us to introduce the latest, state-of-the-art manufacturing processes and the technologies that will enable Fulton to create the energy saving systems of the future.

He goes onto say that, as a result of the move, the manufacture of larger boiler pressure vessels for UK and Export markets will return to Bristol from Fulton’s facilities in China.

The new UK headquarters, which creates a centre of excellence for the company’s heat transfer products, will provide comprehensive customer support, from applications advice and sales processing, through to delivery. Experienced teams are available to help with enquiries for the company’s range of thermal fluid, fuel-fired and electric steam boilers, hot water boilers and ancillary products.

The site will also accommodate a new training and seminar facility created to enable qualified staff to keep customers up-to-date with the latest products and applications; and host the company’s recently announced City & Guild certified training courses, which offer a mix of theoretical and practical operational assignments.

The new Fulton facility is located at 5 Fernhurst Road, Bristol, BS5 7FG. Telephone/fax numbers and email addresses are not affected by the move.

Scottish CEA Conference is Success for Byworth

The seventh in the series of successful CEA (Combustion Engineering Association) Conferences was held in Perth, Scotland at the end of April. Visitors to the Byworth Boilers stand were brought up to speed with the new BG01 Health & Safety Executive guidelines for steam and hot water boiler plant as well as being shown the importance of the correct training.

The Health & Safety at Work Act specifies that employees must be provided with adequate training following the introduction of new procedures, systems or technology and that training must be refreshed on a regular basis. In addition PUWER-Use and maintenance of equipment states that everyone who uses and maintains work equipment needs to be adequately trained if new technology or new equipment is introduced.

For insurance purposes employers must ensure all operators are adequately trained and must be able to show evidence of that training. From a health and safety point of view it is essential all operators are trained to a competent standard in the event of any involvement of the Health & Safety Executive.

As part of the programme of workshops, held throughout the day, Byworth’s Ian Roberts, spoke on Risk Assessment and Risk Management relating to Boiler House and Steam Systems. In his talk he stressed the factors to be considered when designing and operating boiler houses and steam systems from a risk assessment perspective.

Commenting on the success of the conference Tony Green said “The whole event was extremely well organised by David and Julie Kilpatrick and well attended by representatives from a good cross section of relevant industries, many of whom had a need for the training facilities we provide.”

Gordon Smith, from The University of Dundee, won a place on a Byworth Boiler Operator Training Course in a special business card free draw.

Byworth offers a choice of training courses for both new and experienced boiler operators. The Certified Industrial Boiler Operator Course for example is the only national boiler operator qualification and has been developed by the CEA in conjunction with the Health & Safety Executive and the Insurance Industry. It also has the backing of the Carbon Trust.

For further information on all Byworth’s training course options please phone the Training Sales Team on 01535 665225 or email training@byworth.co.uk

Vital Energi spreads the CHP word in Hampshire

Sustainable energy specialists from Vital Energi provided industry insight into the issues currently affecting the development of Combined Heat and Power (CHP) in the UK during a presentation at an event organised by Hampshire County Council in April.

The event, which took place on Monday 15th April 2013 at Ashburton Hall, Hampshire County Council, QEII Building, Southampton SO23 8UJ, is part of the Ecotec21 project which seeks to improve energy efficiency by promoting Combined Heat and Power (CHP) from many fuels including biomass.

Vital Energi’s Mark Howell and Howard Roche gave a presentation at the event on the ‘Use of Biomass in Combined Heat and Power District Energy Schemes’. They demonstrated the cost, technology and legislative barriers for biomass CHP, in the UK, and covered the challenges and opportunities presented by government incentives.

The aim of the Hampshire County Council’s event was to bring together local authorities, universities, research institutions, government funded organisations, energy and facility managers, architects and elected members to explore how delegates from the UK and France can collaborate and compare the methods and practicalities of establishing CHP district energy schemes in their respective regions.

Ian Whitelock, joint managing director of Vital Energi, commented: "Vital Energi is always happy to give our time and expertise to educational events, like this conference, that demonstrate the benefits of using renewable CHP as a technology in district heating schemes.

"As a market leader in sustainable energy we understand the importance of sharing our expertise with public and private sector organisations and providing the guidance that is fundamental to the successful delivery of their community energy schemes."

Scotland’s Energy Minister, Fergus Ewing, launched the Scottish Government’s District Heating Action Plan in May while visiting the CHP energy centre at the new Athletes’ Village for Glasgow’s 2014 Commonwealth Games.

The Athletes’ Village includes a new district heating network designed and built by Vital Energi on behalf of developers City Legacy Consortium. The £10 million system is the largest district heating network ever installed for a new build development and is nearly double the size of the network installed at the Olympic Village in London.

It was installed, commissioned, tested and operational a year in advance of the games and will provide heat and hot water to the Emirates Arena and Sir Chris Hoy Velodrome, the 704-home Athletes’ Village, a 120 bed care home and to an additional 750 new homes that will be built after the Commonwealth Games finish as part of the Legacy phase of this significant construction project.

The Scottish Government’s District Heating Action Plan sets a clear roadmap for how it will support the growth of district heating networks throughout Scotland to help reduce energy bills and carbon emissions.

The plan was devised by an expert commission which included Howard Roche of Vital Energi. It proposes the creation of a Heat Network Partnership that will help to develop a project investment pipeline to secure support from the Green Investment Bank Renewable Energy Investment Fund, and to identify funding opportunities from European and UK funding sources, such as the European Regional Development Fund.

It also includes a Call for Evidence on the investment needed in heat networks over the next few years. In particular, to address the barriers to creating large-scale integrated heat networks.

Fergus Ewing said: "District heating is an important means of achieving both carbon emission and fuel poverty targets as well as contributing to the development of a low-carbon economy and local economic regeneration.

"Working with our partners, district heating will help to deliver our overall vision of a largely decarbonised heat sector by 2050, with significant progress by 2030. The switch to district heating is already helping take thousands of households in places like Glasgow and Aberdeen out of fuel poverty.

"We are already seeing the benefits at the Commonwealth Games Athletes’ Village where a £10 million district heating energy system will provide heating and hot water through underground pipes."

Ian Whitelock, joint managing director of Vital Energi, commented: "We are delighted the Scottish Government chose the 2014 Commonwealth Games Athletes’ Village for the launch of its District Heating Action Plan.

"We are very proud of our work on this scheme which has recently been named Best Green Initiative at the Homes for Scotland Awards. This success is largely attributed to our district heating system which will reduce carbon emissions by 35 per cent and is expected to result in energy bills around 40 per cent lower than any other power methods.

"The Scottish Government’s new District Heating Action Plan shows its commitment to implementing district heating in major urban areas and we welcome the opportunity to help it achieve its goal."

Community Heating helps Glasgow's Athletes' Village win Top Housing Award

Vital Energi’s bespoke low carbon community heating system has helped the Athletes’ Village for the 2014 Commonwealth Games in Glasgow win the award for Best Green Initiative at the prestigious Homes for Scotland Awards 2013.

The awards celebrate the success of the home building industry across a range of issues which remain key to the sectors ongoing drive towards recovery. Accolades were given to stand-out submissions which showcased new and innovative approaches to the low carbon and environmental agendas, housing delivery, partnership working and customer awareness.

The Athletes’ Village for the 2014 Commonwealth Games in Glasgow is being delivered by the City Legacy Consortium which is made up of house building companies Mactaggart and Mickel, CCG, Cruden and WH Malcolm.

Around 6500 athletes and officials will stay in the Athletes’ Village during the games which have been billed as the ‘greenest games ever’.

The new homes are being built to achieve "eco homes excellent" standard and deliver a 60 per cent reduction in carbon emissions. The addition of Vital Energi’s low carbon community heating system should increase the level of carbon reduction to 95 per cent.

The £10 million community heating system is the largest district heating network ever installed for a new build development and is nearly double the size of the network installed at the Olympic Village in London.

It will provide heat and hot water to the Emirates Arena and Sir Chris Hoy Velodrome, the 704-home Athletes’ Village, a 120 bed care home and to an additional 750 new homes that will be built after the Commonwealth Games finish as part of the Legacy phase of this significant construction project.

Vital Energi has recently been awarded a new £1.3 million contract to install an additional CHP engine in the energy centre to provide extra capacity during the games and for the Legacy phase.

Ian Whitelock, joint managing director of Vital Energi, commented: "We are delighted to have contributed to the success of this significant construction project and to have been trusted with the expansion of the energy centre to accommodate additional development.

"Vital Energi is very proud to be assisting Glasgow with its ambitions to become one of Europe’s most sustainable cities and leave a lasting games legacy for future generations."

Specialist sustainable energy company, Vital Energi, has won the contract to create the district heating network for Center Parcs’ fifth holiday village in the UK, due to open in spring 2014.

The new £250 million Woburn Forest Center Parcs in Bedfordshire is currently under construction and is being built to an exemplary level of energy efficiency and sustainability standards.

Center Parcs Woburn Forest will comprise of 625 low carbon forest lodges and a 75-bed hotel and spa. It will also include indoor and outdoor sports facilities, restaurants, retail units, a lake and swimming pool.

Birse Civils, the Balfour Beatty Company which has won the £26 million contract to build the infrastructure for the village, has awarded the contract for designing, supplying and installing the main district heating network to Blackburn-based Vital Energi.

Work began on installing the 18km of pre-insulated steel and flexible plastic pipes in June 2012 and is due for completion by December 2012.

To accommodate the unique geography of the holiday village, which is being built within a forest, Vital Energi has worked with the client to design a district heating network which navigates a complex environment and includes an unprecedented amount of specially-made curved steel pipe.

Ian Whitelock, joint managing director of Vital Energi, commented: "Vital Energi is delighted to have been awarded this prestigious contract and to be able to use our expertise to help Center Parcs realise its ambition of a more sustainable heating system for its new Woburn Forest holiday village.

Woburn Forest will be an exemplary sustainable tourism destination. Center Parcs is investing in energy efficiency and renewable technologies to achieve its aim of consuming 25 per cent less energy than the average existing village.

Center Parcs UK Limited welcomed 1.6 million visitors to its four existing villages last year and still managed to achieve 7 per cent carbon reduction across the company. This year Center Parcs is aiming for a four per cent carbon reduction.

Center Parcs was ranked joint number one in the Carbon Reduction Commitment (CRC) Performance League Table, published for the first time last year. The league table ranks companies and organisations on their efforts to improve energy efficiency.

No ifs, No T-butts…introducing the Composite Steam Boiler...

With its unique design features optimising efficiency and saving plant owners money, the ICI Caldaie Composite Steam Boiler is fast becoming the boiler of choice throughout the Water Industry.

The ICI Composite Boiler range has been selected for some of the highest-profile enhanced Bio Gas projects currently being delivered in the UK, including Beckton & Crossness THP projects and the 4 Anglian Water AMP 5 Special Projects (Basildon, Cliff Quay, Colchester and Pye Wipe STWs). It is also being considered for a number of other on-going schemes.

In addition, a worldwide THP technology provider has recognised the numerous advantages that come with an ICI Caldaie Composite Boiler.

The first feature of the composite boiler is the fired section, consisting of a three pass and fully wet back design. ICI Caldaie incorporates all its standard firetube boiler design features into its composite boilers, ensuring a long and reliable life-cycle.

The Benefits

The main boiler body is manufactured with flanged tube plates – rather than traditional t-butt welds - to ensure maximum security and reduced stress points.

Front doors fitted to the boiler by double pin joint hinges that can be opened without removing the burner.

Feed water inlet thermal sleeve and stainless steel sparge pipe

Internal steam separator to ensure dryness fraction of 99.5%.

Arced internal support brackets to reduce stress points.

Combining a waste heat and fired boiler together, this ICI Caldaie product has a separate section for utilising high-grade waste heat from new CHP assets. The waste heat operates as the primary fuel source to generate the provision of free steam for on-site process requirements as opposed to using non-renewable fuel sources such as gas and oil, which obviously come at an additional cost.

Efficiency of the composite unit can be improved, typically in excess of 5%, with the addition of flue gas economisers.

ICI Caldaie UK Ltd. is a member of the Torishima Global Group of companies, having been part-acquired by Torishima (Europe) Projects (TEP), www.torishimaprojects.co.uk) in the autumn of 2012.

TEP specialise in the turnkey delivery of steam and hotwater boilerhouse systems and associated process plant.

Boiler Operation Accreditation courses in Qatar

Hamad Medical Corporation’s boiler operatives are the first to receive accredited qualification outside of the UK. David Kilpatrick, director of the Combustion Engineering Association reports.

Leaving aside the magic of steam trains and the “proper engineering” of working museum exhibits, it is easy to miss the principal applications of steam. Steam is a very efficient method of transferring energy from a boiler to multiple locations where a wide variety of processes may need heat energy. Hot water can do this, but steam can pack so much more energy into the same volume and has the bonus of being ready for sterilisation of plant and products if required. That is why steam tends to be the energy vector of choice in hospitals.

The UK’s Health and Safety Executive (HSE), The Combustion Engineering Association (CEA) and the Safety Assessment Federation (Safed), manufacturers, training centres and employers all saw the need to create best practice guidance in safe boiler operation that everyone could support. The UK’s Combustion Engineering Association (CEA) provides the independent platform to bring all parties together and subsequently issue certificates to qualified operatives. That certificate is in the name of the Boiler Operation Assessment Scheme (BOAS), which also accommodates the supervisors and Managers.

Green Energy & Environmental Services Co. (GEESC) is an authorised Qatari training and consultancy company that delivers training and consultancy services to the major industries and governmental entities in Qatar. With a staff of over 800, many of whom have responsibility for operating the steam boilers across HMC’s sites throughout Qatar, Robert Smith, head of facilities at the Hamad Medical Corporation, was very keen to have some of his key staff qualified to international standards. Smith said: “with so much development and growth in the medical facilities market, I was becoming aware that sometimes my staff, in this case steam boiler operatives, had not received much formal training, or at least not for some time; so I set about formalising a training and certification programme to ensure that everyone was aware of the current best practice.”

While the engineers were competent with lots of experience and were made up of graduate engineers, navy, merchant navy, electrical engineers and some trained by US naval, there were gaps in the training they had received.

GEESC received a request for quotation from Hamad Medical Corporation for the delivery of BOAS training and subsequently contacted the CEA in the UK to find a suitable supplier for the course. Some of the eight BOAS approved training providers submitted proposals to GEESC for the work and after a selection process, Byworth Boilers were chosen to bid with GEESC to deliver the training in Doha. GEESC went on to win the project for delivering the BOAS Training to Hamad Medical Corporation.

GEESC is the authorised representative for Byworth Boilers in Qatar. The training carried out by Steve Blackburn of Byworth Boilers, in Doha, was the first BOAS course for 40 candidates from the Hamad Medical Corporation (HMC). The training took place at their Engineering Training Department, Hamad Medical City, Doha. The candidates were from various sites across Qatar including from the Doha medical centre. Each of the two cohorts took five days (Sunday – Thursday) to complete and the qualification which is likened to taking a driving test but not the lessons leading to that test, as all candidates have to have previous experience in order to qualify for the course.

Candidates spent three days in the training room and half a day in the Central Boiler House for practical ‘hands on’ experience and training. The first of the two courses had 19 attendees with 23 for the second (40 took the exams), and for the practical work the trainees were in groups of 5 or 6. All four exam papers were taken at the Engineering Training Centre, with assessments done by Iain Summerfield of Kiwa GASTEC at CRE Cheltenham took place over the following 5 days. Iain followed exactly the same process that we use in the UK, where strict separation is maintained between the training programme and the ultimate assessment of competence.

The very enthusiastic trainees ranged from senior engineers to boiler operators and all were from either the Philippines or India. Maire Gallen organised the training for Green Energy and Floriano Kempis for HMC, and the course was authorised by Robert Smith, director of engineering for HMC. Abdulla al Kubaisi is the head of training for HMC, with more training programmes anticipated to follow.

The final part of the process is the CEA registration, done by CEA officials based at its new offices in Sedgefield. The information supplied by the candidate to the training centre, the examination results and Assessor’s report, all of which go toward verification that the candidate justify registration under BOAS.

Successful candidates receive a CEA certificate, confirming BOAS accreditation valid for five years, together with an identity card to confirm their status.